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Question Bank Machine Design A: Numerical Problems: Problems On Pin, Cotter and Knuckle Joints
Question Bank Machine Design A: Numerical Problems: Problems On Pin, Cotter and Knuckle Joints
MACHINE DESIGN
A: Numerical Problems:
1. Two rods, made of plane carbon steel 30C8 (fyt = 400 N/mm2), are to be connected by
means of a cotter joint. The diameter of each rod is 40 mm. Assuming yield strength in
compression = 1.5 fyt, yield strength in shear = 0.5 fyt and factor of safety = 5,
calculate:
a) Inside diameter of socket,
b) Outside diameter of socket, and
c) Diameter of socket collar.
2. Design a sleeve and cotter joint to resist a tensile load of 60 kN. All parts of the joint
are made of same material with the following allowable stresses:
2 2 2
ft = 60 N/mm ; fs = 70 N/mm ; and fc = 125 N/mm .
3. Design a gib and cotter joint with two gibs to resist a safe tensile load of 50 kN. The
material of the gibs, cotter and rods is same for which the allowable safe stresses are :
2 2 2
fc = 60 N/mm , ft = 25 N/mm and fs = 20 N/mm .
4. Design a cotter joint for fastening the piston rod to the cross head of the engine having
cylinder diameter 0.24 m and steam pressure is 0.7 N/mm2. The thickness of the cotter
is to be 0.3 times piston rod diameter at the point where the cotter is located.
Allowable stresses in tension, shear and compression are 50 N/mm2; 40 N/mm2 and 80
N/mm2 respectively.
5. A cotter foundation bolt is subjected to a maximum pull of 45 kN. The bolt and the
cotter are made of steel FeE300(fyt = 300 N/mm2) and the factor of safety is 5. The
yield strength in compression can be assumed to be twice of the tensile yield strength.
The thickness of the cotter is one-fourth of the diameter of enlarged end of the bolt.
Calculate:
a) The diameter of the bolt,
b) The diameter of the enlarged end of the bolt,
c) The thickness and the width of the cotter, and
d) The compressive stress between the cotter and the bolt. Is it safe?
6. Two round tie rods of a roof truss are connected by means of a coupling joint. The
maximum pull in the rod is 50 kN. Assuming that the allowable stress in tension,
compression and shear as 70 N/mm2; 80 N/mm2 and 30 N/mm2 respectively, design
the joint. How much would be the rods drawn together for one turn of the coupler?
8. Design the suspension link of a structure, which is subjected to a load of 160 kN. The
allowable stresses in tension, shearing and crushing are 100 N/mm2; 75 N/mm2 and
150 N/mm2 respectively. The width of the link is 50 mm.
9. Design a cotter joint to connect a piston rod to the crosshead. The maximum steam
pressure on the piston rod is 35 kN. Assuming that all the parts are made of the same
material having the following permissible stress: σt = 50 MPa ; τ = 60 MPa; and σc =
90 MPa
10. The big end of a connecting rod is subjected to a load of 40 KN. The diameter of the
circular part adjacent to the strap is 50 mm. Design the joint assuming the permissible
tensile stress in the strap as 30 Mpa and the permissible shear stress in the cotter and
jib as 20 Mpa.
1. A steam engine cylinder of 0.30m diameter is supplied with steam at 1.5 N/mm2. The
cylinder cover is fastened by means of 8 bolts of size M20. The joint is made leak
proof by means of suitable gaskets. Find the stress produced in the bolts.
2. A mild steel cover plate is to be designed for an inspection hole in the shell of a
pressure vessel. The hole is 0.12m in diameter and the pressure inside the vessel is 6
N/mm2. Design the cover plates along with the bolts. Assume allowable tensile stress
for mild steel as 60 N/mm2 and for bolt material as 40 N/mm2.
4. A screw press is to exert a force of 40 kN. The unsupported length of the screw is 400
mm. Nominal diameter of the screw is 50 mm. The screw has square threads with
pitch equal to 10 mm. The material of the screw and nut are medium carbon steel and
cast iron respectively. For the steel take ultimate crushing stress as 320 N/mm2, yield
5. Design a screw jack for lifting a safe load of 150 kN through a maximum lift of 350
mm. The elastic strength of the material of the screw may be taken as 240 N/mm2, in
tension and compression and 160 N/mm2 in shear. The nut is to be made of phosphor
bronze for which the elastic strengths in tension, compression and shear are 130, 115
and 100 N/mm2 respectively. Safe crushing stress for the material of the body is 100
N/mm2. The co-efficient of friction for the screw as well as collar may be taken as
0.15. The factor of safety for both screw and nut may be taken as 2. The design should
include the design of (i) screw, (ii) nut and (iii) cup and handle. Also find out the
efficiency of the screw jack.
You can take the help of the following standard chart for basic dimensions of the
square threads in “mm”.
Nominal diameter of 40 42 44 46 48 50 52 55 58 60
bolt (mm).
Core diameter of bolt 33 35 37 38 40 42 44 46 49 51
(mm).
Pitch of the bolt (mm). 7 7 7 8 8 8 8 9 9 9
1. A triple riveted lap joint with zig-zag riveting is to be designed to connect two plates
of 6 mm thickness. Determine the diameter of the rivets, pitch of rivets and the
distance between the rows of rivet. Indicate how the joint will fail. Assume ft = 120
N/mm2; fs = 100 N/mm2 and fc = 150 N/mm2.
2. Design the longitudinal and circumferential joint for a boiler whose diameter is 2.4 m
and is subjected to a pressure of 1N/mm2. The longitudinal joint is a triple riveted butt
joint with an efficiency of about 85% and the circumferential joint is a double riveted
lap joint with an efficiency of about 70%. The pitch in the outer rows of the rivets is to
be double than in the inner rows and the width of the cover plates is unequal. The
allowable stresses are: ft = 77 N/mm2; fs = 56 N/mm2; and fc = 120 N/mm2.
Assume that the resistance of rivets in double shear is 1.875 times that of single shear.
Draw the complete joint.
3. A triple riveted butt joint with equal double cover plates (zig-zag riveting) is used for
the longitudinal joint of a Lancashire boiler of 2.5m internal diameter. The working
steam pressure is 1.12 N/mm2 and the efficiency of the joint is 85%. Calculate the
4. Two mild steel tie bars, for a bridge structure are to be joined by means of a butt joint
with double straps. The thickness of the tie bar is 12 mm and carries a tensile load of
400 kN. Design the joint completely taking the allowable stresses as ft = 100 N/mm2; fs
= 75 N/mm2; and fc = 150 N/mm2.
Fig.10
7. A steel plate, 80 mm wide and 10 mm thick, is joined to another steel plate by means
of a single transverse and double parallel fillet welds as shown in Fig.14. The strength
of the welded joint should be equal to the strength of the plates to be joined. The
permissible tensile and shear stresses for the weld material and the plates are 100 and
70 N/mm2 respectively. Find the length of each parallel fillet weld. Assume that the
tensile force passes through the centre of gravity of three welds.
Fig.14
8. The fillet welds of equal legs are used to fabricate a ‘T’ as shown in Fig.15(a) and (b),
where ‘s’ is the leg size and ‘l’ is the length of the weld.
Locate the plane of maximum shear stress in each of the following loading patterns.
(i) Load parallel to the weld (neglect eccentricity), and
(ii) Load at right angles to the weld (transverse load).
Find also the ratio of these limiting loads.
1. A solid steel shaft is supported on two bearings 1.8 m apart and rotates at 250 r.p.m. A
20° involute gear D, 300 mm pitch circle diameter is keyed to the shaft at a distance of
150 mm to the left of the right hand bearing. Two pulleys B and C are mounted on the
shaft at distances of 600 mm and 1350 mm respectively to the right of the left-hand
bearing. The diameters of the pulleys B and C are 750 mm and 600 mm respectively.
30 kW is supplied to the gear, out of which 20 kW is taken-off at the pulley C and 10
kW from pulley B. The tangential force acting on the gear is vertically downward. The
drive from B is vertically downward while from C the drive is downward (front) at an
angle of 60° to the horizontal. In both cases the belt tension ratio is 2 and the angle of
lap is 180°. The combined fatigue and shock factors for torsion and bending may be
taken as 1.5 and 2 respectively.
Design the shaft taking allowable stresses in tension and shear as 84 N/mm2 and 42
N/mm2 respectively.
3. Consider the forces acting on the intermediate shaft shown in Fig.18 of problem 3.
The maximum permissible radial deflection at any gear is limited to ( 0.01m ), where
4. Design and draw a muff coupling which is used to connect two steel shafts
transmitting 25 kW power at 360 r.p.m. The shafts and keys are made of plain carbon
steel 30C8 ( fyt = fyc = 400 N/mm2). The sleeve is made of grey cast iron FG200 ( fut =
200 N/mm2). The factor of safety for the shafts and keys is 4. For sleeve the factor of
safety is 6 based on ultimate strength
5. A protected type flange coupling is used to transmit 15 kW power at 200 r.p.m. The
design torque is 125% of the rated torque. The shafts, keys and bolts are made of plain
carbon steel 40C8 (fyt = 380 N/mm2) and the factor of safety is 5. The yield strength in
compression can be taken as 150% of the tensile yield strength and the yield strength
in shear is 50% as that of tension. The flanges are made of grey cast iron of grade
FG200 (fut = 200 N/mm2) and the factor of safety is 6. The keys have square cross-
section. Design the coupling and specify the dimensions of its parts.
1. Design an open flat belt drive to transmit 120 kW for a system consisting of two
pulleys of diameters 0.9m and 1.2m, centre distance of 3.6m, a belt speed of 20 m/sec,
co-efficient of friction 0.3, a slip of 1.2% at each pulley and 5% friction loss at each
shaft and of 20% overload. Take the density of the belt material is 1 gm/c.c., width of
2. A blower is driven by an electric motor through a belt drive. The motor runs at 450
r.p.m. For this power transmission, a flat belt of 8 mm thickness and 250 mm width is
used. The diameter of the motor pulley is 350 mm and that of the blower pulley is
1350 mm. The centre distance between these pulleys is 1850 mm and an open belt
configuration is adopted. The pulleys are made of cast iron. The co-efficient of friction
between the belt and pulley is 0.35 and the permissible stress for the belt material can
be taken as 2.5 N/mm2. The mass of the belt is 2 kg/m length. Find the maximum
power transmitted without belt slipping in any one of the pulley.
3. A 25 kW, 900 r.p.m. motor drives a centrifugal pump at 290 r.p.m. by means of a
leather belt. The pulleys are of cast iron and are 1.2 metre centre distance. The pulleys
of diameter less than 150 mm should not be used. The co-efficient of friction between
the leather belt and the cast iron pulley is 0.35, and the belt weighs 0.9 gm/cm
width/cm length. The maximum permissible tension per cm width of the belt is 100 N.
The drive is to be designed for 20% overload.
Determine the pulley diameters, the required width and the length of the belt. Also,
find the initial tension with which the belt is to be mounted on the pulleys.
4. An overhung cast iron pulley transmits 7.5 kW at 400 r.p.m. The belt drive is vertical
and the angle of wrap may be taken as 180°. The co-efficient of friction between the
belt and pulley is 0.25. Determine:
(i) Diameter of the pulley taking the density of cast iron is 7200 Kg/m3.
(ii) Width of the belt assuming thickness of 10 mm and the density of belt material
as 1000 kg/m3.
(iii) Diameter of the shaft, if the distance of the pulley centre line from the nearest
bearing is 300 mm.
(iv) Dimensions of the key for securing the pulley on to the shaft.
(v) Size of the arm six in number.
The section of the arm may be taken as elliptical, the major axis being twice the minor
axis. The following stresses may be taken for the design purposes:
Shaft and key : Tension and compression ---- 80 N/mm2.
Shear ---- 50 N/mm2.
Belt : Tension ---- 2.5 N/mm2.
Pulley rim : Tension ---- 4.5 N/mm2.
Pulley arms : Tension ---- 15 N/mm2.
5. Two shafts whose centres are 1 m apart are connected by a V- belt drive. The driving
pulley is supplied with 125 kW and has an effective diameter of 0.3 m. It runs at 1000
r.p.m while the driven pulley runs at 375 r.p.m. The angle of groove on the pulleys is
40°. Permissible tension in 400 mm2 cross-sectional area belt is 2.1 N/mm2. The
material of the belt weighs 1.11 gm/c.c. They driven pulley is overhung, the distance
of the centre from the nearest bearing being 200 mm. The co-efficient of friction
Problems on Springs:
1. Design and draw a valve spring of a petrol engine for the following operating
conditions:
Spring load when the valve is open = 400 N.
Spring load when the valve is closed = 250 N.
Maximum inside diameter of the spring = 25 mm.
Length of the spring when the valve is open = 40 mm.
Length of the spring when the valve is closed = 50 mm.
Maximum permissible shear stress = 400 N/mm2.
Modulus of rigidity = 80 kN/mm2.
2. Design a helical spring for a spring loaded safety valve for the following conditions:
Operating pressure = 1 N/mm2.
Maximum pressure when the valve is blows off freely = 1.075 N/mm2.
Maximum lift of the valve when the pressure is 1.075 N/mm2 = 6 mm.
Diameter of the valve seat = 100 mm.
Maximum shear stress = 400 N/mm2.
Modulus of rigidity = 86 × 103 N/mm2.
Spring index = 5.5.
The standard thickness of leaves are: 5, 6, 6.5, 7, 7.5, 8, 9, 10, 11 etc. in mm.
6. A semi-elliptical spring has ten leaves in all, with the two full length leaves extending
625 mm. It is 62.5 mm wide and 6.25 mm thick. Design a helical spring with mean
diameter of coil 100 mm which will have approximately the same induced stress and
deflection for any load. The Young’s modulus for the material of the semi-elliptical
spring may be taken as 200 N/mm2and modulus of rigidity for the material of the
helical spring is 80 kN/mm2.
2. The hydraulic press, having a working pressure of water as 16 N/mm2 and exerting a
force of 80 kN is required to press materials up to a maximum size of 800 mm × 800
3. Design a circular flanged pipe joint for a cast iron pipe with internal diameter 200 mm
is subjected to a fluid pressure of 0.7 N/mm2. The flange is connected by means of
eight bolts. The pitch circle diameter of the bolts is 290 mm. Take the allowable
tensile stress in the pipe material is 14 N/mm2 and in the bolts is 60 N/mm2.
4. Design an oval flanged pipe joint for pipes of internal diameter 50 mm subjected to a
fluid pressure of 7 N/mm2. The maximum tensile stress in the pipe material is not to
exceed 21 N/mm2 and in the bolts 28 N/mm2.
5. The pressure within the cylinder of a hydraulic press is 8.4 N/sq. mm. The inside
diameter of the cylinder is 25.4 mm. Determine the thickness of the cylinder wall, if
the allowable tensile stress is 17.5 Mpa.
B: Multi-Choice Questions: